Abstract:

Apparatus and methods for assembling solar receiving tubes in the field
are described. In one embodiment, a welder is provided having
longitudinally adjustable clamps that permit the easy restraining and
adjustment of tube position for welding. In another embodiment, a system
for moving along the length of a solar collector and sequentially welding
tubes is described.

Claims:

1. An apparatus for welding the ends of a first and a second heat
collection element (HCE), where the first HCE includes a first outer
collar and a concentric and inner tube and the second HCE includes a
second outer collar and a concentric and inner tube, said apparatus
comprising:an orbital weld head having an electrode;a first mechanism
including a first clamping surface slidably attached to the orbital weld
head and adapted to restrain the first collar;a second mechanism
including a second clamping slidably attached to the orbital weld head
and adapted to restrain the second collar; andwhere said first mechanism
and said second mechanism are adjustable to translate accepted first HCE
and second HCE in a longitudinal HCE direction and present the butted
ends of the first inner tube and second inner tube to said electrode.

2. The apparatus of claim 1, where said first mechanism or said second
mechanism includes a lead screw that moves the respective clamping
surface relative to the weld head.

3. The apparatus of claim 1, where said first mechanism and said second
mechanism are removably attached to said weld head.

4. The apparatus of claim 1, where said first mechanism and said second
mechanism each include an outer portion connected to the weld head and an
inner portion including said respective clamping surface.

5. The apparatus of claim 4, where said weld head includes a first clamp
and a second clamp, where said outer portion of said first mechanism is
attached to the first clamp, and where said outer portion of said second
mechanism is attached to said second clamp.

6. An apparatus for welding the ends of a first and a second heat
collection element (HCE), where the first HCE includes a first outer
collar and a concentric and inner tube and the second HCE includes a
second outer collar and a concentric and inner tube, said apparatus
comprising:a weld head;a first means for clamping the first collar and
longitudinally positioning the ends of an accepted first HCE; anda second
means for clamping the second collar and longitudinally positioning the
ends of an accepted second HCE;such that the means permit locating the
ends of the first HCE and second HCE for welding by the weld head.

7. The apparatus of claim 6, where said first means includes a clamping
surfaces for clamping the first collar, where said second means includes
a clamping surfaces for clamping the second collar, and where said first
means or said second means includes a lead screw that longitudinally
translates one of the clamping surfaces relative to the weld head.

8. The apparatus of claim 6, where said first means and said second means
are removably attached to said weld head.

9. The apparatus of claim 6, where said first means and said second means
each include an outer portion connected to the weld head and an inner
portion including said respective clamping surface.

10. The apparatus of claim 9, where said weld head includes a first clamp
and a second clamp, where said outer portion of said first means is
attached to the first clamp, and where said outer portion of said second
means is attached to said second clamp.

11. An apparatus for welding the ends of a first and a second heat
collection element (HCE), where the first HCE includes a first outer
collar and a concentric and inner tube and the second HCE includes a
second outer collar and a concentric and inner tube, said apparatus
comprising:a first mechanism for accepting the first outer collar;a
second mechanism for accepting the second outer collar; anda weld
head,where said first mechanism and second mechanism are attached to said
weld head, andwhere at least one of said first mechanism and said second
mechanism is adjustable to translate the accepted HCE in a longitudinal
HCE direction,such that the first and second HCEs are translatable to
position the ends of the first inner tube and second inner tube for
welding by said weld head.

12. The apparatus of claim 11, where said first mechanism includes a first
clamping surface adapted to restrain the first collar, and where said
second mechanism includes a second clamping surface adapted to restrain
the second collar.

13. The apparatus of claim 12, where said at least one of said first
mechanism and said second mechanism includes a lead screw that moves the
respective clamping surface relative to the weld head.

14. The apparatus of claim 11, where said first mechanism and said second
mechanism are adapted for attachment to the weld head.

15. The apparatus of claim 12, where said first mechanism and said second
mechanism each include an outer portion connected to the weld head and an
inner portion including said respective clamping surface.

16. The apparatus of claim 15, where said weld head includes a first clamp
and a second clamp, where said outer portion of said first mechanism is
attached to the first clamp, and where said outer portion of said second
mechanism is attached to said second clamp.

17. The apparatus of claim 11, where said weld head is an orbital weld
head.

18. An apparatus for welding the ends of a first and a second heat
collection element (HCE) using a weld head, where the first HCE includes
a first outer collar and a concentric and inner tube and the second HCE
includes a second outer collar and a concentric and metal tube, said
apparatus comprising:a first mechanism for accepting the first outer
collar and adapted for attachment to the weld head; anda second mechanism
for accepting the second outer collar and adapted for attachment to the
weld head;where, when said first mechanism and said second mechanism are
attached to said weld head, at least one of said first mechanism and said
second mechanism is adjustable to translate the accepted HCE in a
longitudinal HCE directionsuch that the first and second HCEs are
translatable to position the ends of the first inner tube and second
inner tube for welding by said weld head.

19. The apparatus of claim 18, where said first mechanism includes a
clamping surface adapted to restraining the first collar, and where said
second mechanism includes a clamping surface adapted to restrain the
second collar.

20. The apparatus of claim 19, where said at least one of said first
mechanism and said second mechanism includes a lead screw that moves the
clamping surface relative to the weld head.

21. The apparatus of claim 19, where said first mechanism and said second
mechanism each include an outer portion connected to the weld head and an
inner portion includes said clamping surface.

22. The apparatus of claim 21, where said weld head includes a first clamp
and a second clamp, where said outer portion of said first mechanism is
attached to the first clamp, and where said outer portion of said second
mechanism is attached to said second clamp.

23. An apparatus for welding the ends of a first and a second heat
collection element (HCE) in a solar energy system at a height above the
ground, where each HCE includes an outer collar and a concentric and
inner metal tube, said apparatus comprising:a vehicle having a weld head,
a welding power supply, and a platform to enable a user to reach the HCEs
for welding.

24. The apparatus of claim 23, where said vehicle includes arms for
supporting HCEs for welding.

25. The apparatus of claim 23, where said vehicle includes an automatic
self-leveling outrigger.

26. A method of assembling a solar energy system, where the solar energy
system includes an absorber tube formed from a plurality of joined heat
collection elements (HCEs), said method comprising:placing the plurality
of HCEs in the solar energy system;moving a vehicle having a weld head, a
welding power supply, and a platform to enable a user to reach the HCEs
along the HCEs; andwelding adjacent HCEs.

27. The method of claim 26, where adjacent HCEs include a first HCE having
a first outer collar and a concentric and inner metal tube and a second
HCE having a second outer collar and a concentric and inner metal tube,
where said welding welds using an apparatus comprising:a first mechanism
for accepting the first outer collar;a second mechanism for accepting the
second outer collar; anda weld head,where said first mechanism and second
mechanism are attached said weld head, and where at least one of said
first mechanism and said second mechanism is adjustable to translate the
accepted HCE in a longitudinal HCE direction.

28. The method of claim 27, where said weld head is an orbital weld head.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims the benefit of priority under 35 U.S.C.
119(e) to U.S. Provisional Application No. 61/238,195 filed Aug. 30,
2009, which is incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002]1. Field of the Invention

[0003]The present invention generally relates to apparatus and methods for
assembling pipes, and more particularly to methods and systems for
joining tubes for solar receivers.

[0004]2. Discussion of the Background

[0005]Solar thermal power plants may be used to obtain electric power from
the sun. In such plants, the solar flux impinges on tubes through which a
heat exchange medium flows. In some solar thermal power plants, tubes are
situated in a solar collector, such as along the axis of a parabolic
trough. The heated heat exchange medium from the tubes may be used in a
thermodynamic cycle to generate electric power.

[0006]FIG. 1A is a perspective view of a portion of a typical prior art
concentrating solar power plant 100 comprising one or more solar energy
collectors 110 arranged in a field. Each collector 110 includes one or
more trough-shaped structures 113 having a reflective surface 119, two or
more ground supports 111, an absorber tube 115 that extends the length of
the collector, and tube supports 117 that couple the reflector to the
absorber tube. It is not uncommon for each collector 110 to have a length
A of approximately 380 feet (116 meters), a width B of approximately 20
feet (6 meters), and a height off the ground H greater than 10 feet (3
meters).

[0007]Typically, surfaces 119 have a longitudinal axis along length A and
a parabolic shape in a plane perpendicular to the longitudinal axis, and
absorber tube 115 is supported along the axis, such that light normally
impinging on the reflector is focused (or concentrated) on the absorber
tube. A mechanism (not shown) is provided to so rotate reflective surface
119 during the day to direct incident sunlight on absorber tube 115 and
thus optimize the collection of solar energy on the tube.

[0008]Absorber tube 115 is generally hollow to permit the flow of a heat
transfer medium, such as water, salt, or some other liquid or gas, along
the absorber tube, thus collecting the concentrated solar energy. The
exiting heat transfer medium may then, for example, be used to drive a
turbine or heat engine (not shown) to generate electricity.

[0009]The construction of certain solar power plants 100 generally
involves the following steps: 1) placing ground supports 111 in the
field, 2) attaching trough-shaped structures 113 to the ground supports,
and 3) joining absorber tube 115 to tube supports 117. To facilitate
construction, absorber tube 115 may be formed by joining many smaller
tubes that are joined together. The smaller tubes are sometimes referred
to as "solar receiver tubes" or "heat collection elements (HCE)."

[0010]FIG. 2 is a partial sectional side view of a prior art HCE 200, FIG.
3 is an end view of the HCE, and FIG. 4 is a sectional end view of the
HCE. HCE 200 may be, for example and without limitation, a SCHOTT solar
receiver tube model PTR 70 (SCHOTT Solar, Inc., Albuquerque N. Mex.).

[0011]Typically, HCE 200 includes an outer tube 210 having a diameter D
that is capped at each end by a metal flange 215, an inner tube 211 and
that is coaxial with the outer tube, and a metal bellows 213 that
connects the flange and inner tube. Tube 210 is preferably optically
transparent and is made, for example of a glass. Flange 215 is attached
to a bellows 213 that extends to tube 211. Tube 211 is thermally
conductive, and may be formed from a metal, and has a length L and an
inner diameter d, through which a heat transfer medium may flow. Tube 210
is generally transparent to sunlight to facilitate the solar heating of a
heat exchange medium that may flow through glass tube 211, as indicated
by arrows in FIG. 2. Tubes 210 and 211, bellows 213 and flange 215 are
sealed to form a volume 212, which is evacuated to provide a high thermal
insulation between tubes 210 and 211.

[0013]For certain HCEs 200, tube 211 protrudes longitudinally beyond the
end of each flange 215 by a distance S, which it typically from 0.375
inches (10 mm) to 4 inches (0.1 m). The portion of tube 211 that so
protrudes is referred to as a collar 214. Forming an absorber tube 115
requires joining collars 214 of adjacent absorber tubes. In certain other
HCEs 200, the free ends of flange 215 may also have a radial protrusion
at the end.

[0014]FIG. 1B is a perspective view illustrating details of a prior art
solar energy collector 110. Absorber tube 115 is formed from a plurality
of HCEs 200, denoted 200a, 200b, and 200c. The ends of each pair of HCEs
are support by one tube support 117.

[0015]One method for joining HCEs 200 is by orbital welding. One example
of such a welder system is an Arc Machines model 207 power supply
controller (Arc Machines, Inc., Pacoima, Calif.) with its mating 207-CW
cooling package may be used with an Arc Machine 9-7500 welder.

[0016]Due their length, L, and glass components, solar receiver tubes tend
to be fragile, and difficult to join, typically by welding, since the
collars 214 protrude beyond the ends of the glass outer tube 210 by a
relatively small distance from each end. Further, collars 214 are
adjacent to bellows 213, on whose integrity the vacuum of volume 212
depends. In addition, the height C may make it very difficult to place
and manipulate a welder. Solar receiver tube are thus difficult to join,
especially in the field, without damaging the more fragile glass outer
tube 210 or the bellows 213 joining tubes 210 and 211. There is a need in
the art for methods and apparatus that permit the easy and rapid joining
of such tubes to facilitate more efficient assembly of solar energy
systems.

BRIEF SUMMARY OF THE INVENTION

[0017]In certain embodiments, an apparatus for welding the ends of a first
and a second HCE is provided, where each HCE includes an outer collar and
a concentric and inner tube. The apparatus includes: a first mechanism
for accepting the first outer collar; a second mechanism for accepting
the second outer collar; and a weld head. The first mechanism and second
mechanism are attached to the weld head, and where at least one of the
first mechanism and the second mechanism is adjustable to translate the
accepted HCE in a longitudinal HCE direction.

[0018]In certain other embodiments, an apparatus for welding the ends of a
first and a second HCE using a weld head is provided, where each HCE
includes an outer collar and a concentric and inner tube. The apparatus
includes: a first mechanism for accepting the first outer collar and
adapted for attachment to the weld head; and a second mechanism for
accepting the second outer collar and adapted for attachment to the weld
head. When the first mechanism and the second mechanism are attached to
the weld head, at least one of the first mechanism and the second
mechanism is adjustable to translate the accepted HCE in a longitudinal
HCE direction.

[0019]In certain embodiments, an apparatus for welding the ends of a first
and a second HCE is provided. Each HCE includes an outer collar and a
concentric and inner tube. The apparatus includes a weld head, a first
means for clamping the first collar and longitudinally positioning the
ends of an accepted first HCE; and a second means for clamping the second
collar and longitudinally positioning the ends of an accepted second HCE.
The first and second means permit locating the ends of the first HCE and
second HCE for welding by the weld head.

[0020]In yet certain other embodiments, an apparatus for welding the ends
of a first and a second HCE in a solar energy system at a height above
the ground is provided, where each HCE includes an outer collar and a
concentric and inner tube. The apparatus includes: a vehicle having a
weld head, a welding power supply, and a platform to enable a user to
reach the HCEs for welding.

[0021]In certain embodiments, a method of assembling a solar energy system
is provided, where the solar energy system includes an absorber tube
formed from a plurality of joined HCEs. The method includes: placing the
plurality of HCEs in the solar energy system; moving a vehicle having a
weld head, a welding power supply, and a platform to enable a user to
reach the HCEs along the HCEs; and welding adjacent HCEs.

[0022]These features together with the various ancillary provisions and
features which will become apparent to those skilled in the art from the
following detailed description, are attained by the tube joining
apparatus and method of the present invention, preferred embodiments
thereof being shown with reference to the accompanying drawings, by way
of example only, wherein:

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0023]FIG. 1A is a perspective view of a portion of a typical prior art
concentrating solar power plant;

[0031]FIG. 7A is a view of the back of the vehicle of FIG. 6A during a
welding operation;

[0032]FIG. 7B is a cross-sectional view of HCEs near a weld location,
illustrating the use of a traveling purge dam to isolate the region being
welded;

[0033]FIG. 8A is a perspective view of an embodiment of a joining
apparatus;

[0034]FIG. 8B is an exploded perspective view of an embodiment of a
joining apparatus;

[0035]FIG. 9A is an end view of the apparatus of FIG. 8 illustrating the
use of an adjustable FIG. in an open configuration;

[0036]FIG. 9B is an end view of the apparatus of FIG. 8 illustrating the
use of an adjustable clamp in a closed configuration;

[0037]FIG. 10A as an exploded view of an adjustable clamping mechanism
portion;

[0038]FIG. 10B as an assembled view of the adjustable clamping mechanism;

[0039]FIG. 11 is a top view 11-11 of FIG. 9A showing adjacent HCEs prior
to welding within the lower part of a welding apparatus;

[0040]FIGS. 12A, 12B, 12C, and 12D, which are sequential sectional side
views 12-12 from FIG. 11 illustrating one embodiment of a method of
joining HCEs; and

[0041]FIGS. 13A and 13B are side views different HCEs illustrating
variations in HCE dimensions.

[0042]Reference symbols are used in the Figures to indicate certain
components, aspects or features shown therein, with reference symbols
common to more than one Figure indicating like components, aspects or
features shown therein.

DETAILED DESCRIPTION OF THE INVENTION

[0043]In general, embodiments are provided that permit the field welding
of tubes (HCEs) to form absorber tubes of solar energy systems. One
embodiment of an apparatus for field welding tubes is illustrated in
FIGS. 6A, 6B, and 7A, where FIG. 6A is a side view of a field welding
vehicle 600, FIG. 6B is a top view of the field welding vehicle, and FIG.
7A is a view of the back of the vehicle during a welding operation. Field
welding vehicle 600 may be used, for example and without limitation to
field weld a plurality of HCEs 200 to form an absorber tube 115.

[0044]Field welding vehicle 600 includes and/or may supply all of the
electricity and gases needed to operate welder 620. Vehicle 600 may be,
for example and without limitation a modified vehicle such as a cargo van
or box truck. Thus, for example and without limitation, field welding
vehicle 600 may include, but it not limited to, one or all of the
following: a roof air-conditioning 601 for environmental control; a
generator 603 within the vehicle for onboard operations; automatic
self-leveling outriggers 605 to stabilize vehicle in work mode; and a
slide out work platform 610.

[0045]Platform 610 may include one or more of the following: a safety
railing 611, a safety rigging belt; a weld head holder bracket for welder
620; and auxiliary lighting for night work. Platform 610 may also include
support arms 613a and 613b for alignment and support of adjacent HCEs 200
relative to welder 620 during welding, and power actuation of support
arm, by electric, pneumatic, hydraulic means.

[0046]Prior to welding, the HCEs 200 for collector 110 are placed and
secured by tube supports 117 in the approximate location where they will
reside as absorber tube 115. Thus, for example and without limitation,
HCEs 200 are positioned in tube supports 117. Structure 113 is rotated to
a service position to provide access to HCEs 200, as illustrated in FIG.
7A.

[0047]Alternatively, several HCEs 200 may be joined prior to being placed
in collector 110. Thus, two or more tubes may be pre-joined, as
illustrated, without limitation in FIG. 5 as a side view of a
triple-joined HCE 500 in FIG. 5, having an end 501 and an end 503. HCE
500 is formed by welding three HCE 200 (200-1, 200-2, and 200-3).
Specifically, welds 505 are formed at end 203 of HCE 200-1 and end 201 of
HCE 200-2, and at end 203 of HCEs 200-2 and end 203 of HCE 200-3. In
general, the procedure for welding HCE 200 and 500 into collector 110 are
the same.

[0048]Vehicle 600, as shown in FIG. 7A, preferably starts at one end of
collector 110, joins collars 214 of a first set of adjacent ends 201,
203, 501, or 503 (referred to in general as ends 201 or 203), then drives
to the next set of ends for joining and stabilizes the vehicle with
automatic self-leveling outriggers 605.

[0049]As illustrated in FIG. 7A, the height H of absorber tube 115 off the
ground is generally too high above ground level to be easily worked on.
Thus field welding vehicle 600 may include a movable platform 610 to
permit a worker to easily access to HCEs 200.

[0050]A purge gas may be provided to the interior of the HCEs 200 by
flowing the gas through the aligned HCEs. Alternative, as shown in FIG.
7B as a cross-sectional view of HCEs 200 near a weld location, a
traveling purge dam 700 may be used to isolate regions of collars 214a
and 214b being welded. After one weld is completed, dam 700 is pulled
through HCEs 200 to the next weld location.

[0051]FIGS. 6B and 7A illustrate support arms 613a and 613b positioned off
of platform 610 such that a worker may support ends 201, 203 to
facilitate joining the HCEs. Support arms 613a and 612b may include a
cradle, or alternatively clamps, to restrain HCEs 200 near where welding
is to occur, with sufficient spacing to permit access to welding
equipment.

[0052]In one embodiment, a worker places adjacent HCEs in support arms
613a and 613b, and then positions welder 620 for welding. In another
embodiment, welder 620 is manually placed by a worker. In another
embodiment, welder 620 is supported by a "skyhook" or other devices on
vehicle 600.

[0053]In many instances, variations between different HCEs 200 or the
placement in supports 117 requires that adjustments be made to adjacent
tubes prior to welding. Thus, for example, slight longitudinal
adjustments to the position of ends 201, 203 (or 501 and 503) of adjacent
HCEs 200 (or 500) may be required for welding. Longitudinal adjustments
are provided by welder 620.

[0054]In certain embodiments, welder 620 is a welding device that includes
means for clamping the collar and longitudinally positioning the ends of
accepted HCEs for proper welding. Welder 620 may thus include
longitudinally adjustable clamps to accurately position collars 214 of
adjacent HCEs 200 or 500. As one embodiment, which is not meant to limit
the scope of the present invention, FIG. 8A is a perspective views of an
embodiment of a joining apparatus 800, and FIG. 8B is an exploded
perspective view of the joining apparatus. Apparatus 800 includes an
adjustable left clamp 810 and an adjustable right clamp 820, which are
both means for clamping the collar and longitudinally positioning the
ends of accepted HCEs

[0055]Joining apparatus 800 may be generally similar to welder 620, and
may include a joining device, such as an orbital welder 801, an
adjustable left clamp 810 and an adjustable right clamp 820. Thus, for
example, adjustable left clamp 810 may be used to restrain one HCE 200,
adjustable right clamp 820 may be used to restrain an adjacent HCE, and
one or more of the left and right clamps may be used to position the HCEs
respective collars for welding in welder 801.

[0056]In one embodiment, orbital welder 801 may have an electrode 802 that
moves along a circular path during welding to weld collars 214 of ends
201, 203. Clamps 810 and 820 are adapted to restrain a pair of adjacent
HCEs 200 and provide for longitudinal alignment of the HCEs for proper
welding in orbital welder 801.

[0057]In another embodiment, orbital welder 801 includes a left clamp 803,
a left clasp 804, and a left hinge 805, and a right clamp 807, a right
clasp 808, and a right hinge 809. Adjustable left clamp 810 includes the
left clamp 803, clasp 804, and hinge 805, a bottom adjustable clamping
portion 812 and a top adjustable clamping portion 815. Bottom adjustable
clamping portion 812 further includes a portion 812a that is attached to
welder 801 and a portion 812b that moves longitudinally within portion
812a according to the action of a lead screw 813. Portion 812b presents a
bottom clamping surface 814 having a seating surface 811. Top adjustable
clamping portion 815 further includes a portion 815a that is attached to
left clamp 803 and a portion 815b that moves longitudinally within
portion 815a according to the action of a top lead screw 816. Portion
815b presents a top clamping surface 817 having a seating surface 818.

[0058]Adjustable right clamp 820, which is similar to clamp 810, includes
the right clamp 807, clasp 808, and hinge 809, a bottom adjustable
clamping portion 822, and a top adjustable clamping portion 825. Bottom
adjustable clamping portion 822 further includes a portion 822a that is
attached to welder 801 and a portion 822b that moves longitudinally
within portion 822a according to the action of a lead screw 823 (which is
shown FIG. 12A). Portion 822b presents a bottom clamping surface 824
having a seating surface 821. Top adjustable clamping portion 825 further
includes a portion 825a that is attached to right clamp 807 and a portion
825b that moves longitudinally within portion 825a according to the
action of a top lead screw 826 (shown in FIG. 12B). Portion 825b presents
a top clamping surface 827 having a seating surface 828.

[0059]Bottom adjustable clamping portions 812 and 822 are thus fixed to
opposite sides of welder 801, and top adjustable clamping portion 814 and
824 are affixed to clamps 803 and 807, respectively. Clamp 810 and 820
and may be held in a partially locked or fully locked position by clasp
804 and 808, respectively.

[0060]As discussed subsequently, lead screws 813, 816, 823, and 826 may
turned to longitudinally move seating surfaces 811, 818, 821, and 828.
Thus when left clamping surfaces 814 and 817 are closed to restrain
flange 215 of one HCE 200, and right clamping surfaces 824 and 827 are
closed to restrain the flange of an adjacent HCE, lead screws 813, 816,
823, and 826 may be used to adjust the location of a welding electrode
802 relative to the ends of the HCEs

[0061]In certain embodiments, welder 801 and clamps 810 and 820, when
closed about HCEs 200a and 200b, for an enclosure about the welding
location. The enclosure may be used, for example, to provide a purge gas
to the outer portion of collars 214 during welding. In one embodiment,
clamps 810 and/or 820 have components that cooperate to form an enclosure
when clasps 804 and 808 are secured. FIGS. 8A and 8B show an enclosure
portion 831, which is attached to right clamp 810, and enclosure portion
833, which is attached to clamp 820. Enclosure portions 831 and 833
permit clamps 810 and 820 to move separately, and to form an enclosure
when securing HCEs 200a and 200b. In one embodiment, portion 833 may
include a transparent material, such as a glass or plastic, to permit a
user to inspect the placement and/or adjustment of electrode 802 relative
to ends 201 and 203 prior to welding.

[0062]FIGS. 9A and 9B is an end view of apparatus 800 illustrating the use
of adjustable clamp 810. FIG. 9A is an open configuration, in which HCE
200 may be inserted or removed from apparatus 800. FIG. 9B is a closed
configuration, in which top portion is rotated and clasped. As shown in
FIG. 9B, clamping surfaces 814 and 817 form a circular clamping surface
that may be used to retain a flange 215. Likewise, clamp 820 has a
similar open configuration and a closed configuration in which clamping
surfaces 824 and 827 may also be used to retain a flange 215. Surfaces
814, 817, 824, and 827 may be used to electrically collars 214 with
respect to welder 801.

[0063]Adjustable clamping portions 812, 815, 822, and 815 are
independently adjustable in a longitudinal direction (along the axis of
an accepted HCE 200 or 500). Adjustable clamping portions 812, 815, 822,
and 815 are also identical, and are illustrated in FIG. 10A as an
exploded view of an adjustable clamping mechanism adjustable clamping
mechanism portion 1000 and in FIG. 10B as an assembled view of the
adjustable clamping mechanism.

[0064]Adjustable clamping mechanism portion 1000 includes a welder
mounting plate 1010 a slidable sleeve 1020, and a lead screw 1030.
Mounting plate 1010 has a welder mounting surface 1017, a sleeve guide
1015, several guide pins 1011 surrounded by springs 1013, and a treaded
hole 1019. Slideable sleeve 1020 has a semicircular portion 1023 with a
clamping surface 1025 having an innermost edge 1026, holes 1012 and 1028,
and a surface 1027. Lead screw 1030, which may have a knurled head,
passes through hole 1028 and into treaded hole 1019.

[0067]FIG. 11 is a top view 11-11 of FIG. 9A showing adjacent HCEs 200
prior to welding within the lower part of apparatus 800. As shown in FIG.
11, a first HCE 200a is resting in and/or supported by support arm 613a
and a second HCE 200b is resting in and/or supported by support arm 613b.
Flange 215a and 215b are resting against clamp surface 824 and 814,
respectively, with ends 201a and 203b aligned along the centerlines of
HCEs 200a and 200b, and positioned end-to-end near electrode 802 of
welder 801.

[0068]A method of aligning and welding HCEs 200a and 200b is illustrated
in FIGS. 12A, 12B, 12C, and 12D, which are sequential sectional side
views 12-12 from FIG. 11 illustrating one embodiment of a method of
joining HCEs. As shown in FIG. 12A, HCE 200a is positioned with flange
215a on clamping surface 824 and HCE 200b is positioned with flange 215b
on clamping surface 814.

[0069]As is also shown, each flange 215 has a lip 216 that slightly
protrudes radially outwards from the flange. Although not a necessary
part of HCE 200, lip 216 may provide a convenient feature for locating
the HCE. Other techniques for locating HCE 200 within apparatus 800 may
be used, including visual inspection. With electrode 802 located near
ends 201a, 203b, lead screws 813 and 823 are adjusted such that lip 216a
seats against seating surface 821 and lip 216b seats against seating
surface 811.

[0070]FIG. 12A also illustrates the rotation of lead screws 813 and 823 to
longitudinally translate portions 812b and 822b, respectively, relative
to HCEs 200a and 200b. Lead screws 813 and 823 may be adjusted so that
seating surfaces 811 and 821, respectively, are brought in contact with
lips 216a and 216b. In addition, lead screws 813 and 823 may be adjusted
to bring the tip of electrode 802 in alignment with ends 201a and 203a.

[0071]Next, as shown in FIG. 12B, the top right clamp 820 is closed by
rotating right clamp 807 over flange 215a. With clasp 808 loosely
tightened, lead screw 825 is adjusted such that lip 216a seats against
surface 828.

[0072]As shown in FIG. 12c, the top left clamp 810 is closed by rotating
left clamp 803 over flange 215b. With clasp 804 loosely tightened, lead
screw 813 is adjusted such that lip 216b seats against surface 818.

[0073]A final adjustment may now be made, as indicated in FIG. 12D.
Specifically, it is important that lip 216a seats against surfaces 821
and 828, that lip 216b seats against surface 811 and 818, and that ends
201a and 203b align with the orbital motion of electrode 802. Lead screws
813, 816, 823, and 826 are rotated to achieve alignment. In one
embodiment, a portion of enclosure portion 833 is a window 1200, as shown
in FIG. 12D, which allows a user to view the location of electrode 802
during this adjustment. Clasps 804 and 808 are then tightened to lock
apparatus 880 onto HCEs 200 between seating surfaces 814, 817, 824, and
827.

[0074]At this point, the user initiates the welding sequence, which may
include providing an external purge gas within welder 801 and initiating
the movement of electrode 802 about ends 201/203. When the weld in
complete, the external purge gas flow is stopped, clasp 804 is released,
clamp 803 is opened, and then clasp 808 is released and clamp 807 is
opened, and apparatus 800 may be moved to the next weld location. In
certain embodiments, portions 815b and 825b must be moved longitudinally
away from each other to clear weld head 801 and permit clamps 803 and 807
to be opened.

[0075]The importance of being able to make fine adjustments is highlighted
in FIGS. 13A and 13B, which are side views different HCEs illustrating
variations in HCE dimensions. The dimension S is the distance from an
edge of flange 215, which may be lip 216, to end 201 or 203. FIG. 13A
illustrates the case where the ends of adjacent HCE 200a and 200b have
the same dimensions. Thus, the distance S=S1 is the same for each, and
the distance between adjacent lips 216 is G1=2 S1, and the weld occurs at
the midpoint of G1. Importantly, G1 is the space which a welder must fit
to reach collars 214.

[0076]FIG. 13B illustrates another case, were each distance S is different
(one is S1, and the other S2), the total distance between adjacent lips
is G2=S2+S3, and the weld does not occurs at the midpoint, since S2 does
not equal S3. Since it is important that the tip of the weld electrode be
in the vicinity of end 201a/203b, and since flange 205 must be clamped
for welding, it is important that both the spacing and the relative
position of the HCEs and electrode be adjustable, as provided by
apparatus 800.

[0077]Reference throughout this specification to "one embodiment" or "an
embodiment" means that a particular feature, structure or characteristic
described in connection with the embodiment is included in at least one
embodiment of the present invention. Thus, appearances of the phrases "in
one embodiment" or "in an embodiment" in various places throughout this
specification are not necessarily all referring to the same embodiment.
Furthermore, the particular features, structures or characteristics may
be combined in any suitable manner, as would be apparent to one of
ordinary skill in the art from this disclosure, in one or more
embodiments.

[0078]Similarly, it should be appreciated that in the above description of
embodiments of the invention, various features of the invention are
sometimes grouped together in a single embodiment, figure, or description
thereof for the purpose of streamlining the disclosure and aiding in the
understanding of one or more of the various inventive aspects. This
method of disclosure, however, is not to be interpreted as reflecting an
intention that the claimed invention requires more features than are
expressly recited in each claim. Rather, as the following claims reflect,
inventive aspects lie in less than all features of a single foregoing
disclosed embodiment. Thus, the claims following the Detailed Description
are hereby expressly incorporated into this Detailed Description, with
each claim standing on its own as a separate embodiment of this
invention.